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South Main Church of Christ Case Study

Proven Results: Our HVAC Project at South Main Church of Christ

BEFORE: Critical System Failures & Safety Risks

When we arrived at this location, the HVAC system was experiencing a range of mechanical, electrical, and performance issues that impacted reliability, safety, and efficiency. Key problems included:

System Reliability & Performance Challenges

  • The unit frequently tripped on high pressure during hot weather due to an underperforming cooling tower and system imbalance.
  • The compressor was pulling dangerously high amps on one power leg, risking failure.
  • Oil return was poor, with signs of system contamination and disconnected safety controls.
  • The refrigerant system was low, with visible leaks, broken valve cores, and degraded insulation on sensing bulbs.
  • Superheat and subcooling values were unstable, reducing system efficiency and compressor protection.
  • The old condenser water pump could not move enough flow for the system, which also contributed to issues in the system.

Mechanical & Structural Deficiencies

  • Valve caps and cores were leaking throughout the system, and service valves on both the suction and discharge valves were compromised.
  • The discharge line was improperly routed, contributing to excessive vibration and was cracking and releasing the charge up to several times a year.
  • Compressor was rigid-mounted to a steel plate which is fine, but due to the issues found, our mechanical engineer (Deborah Blackall www.gagliardigroup.com) did a vibration study on the machine to determine what course of action would need to be taken.
  • Overflow piping and water lines were damaged or incorrectly installed, requiring complete replacement and reconfiguration.

Electrical & Control System Issues

  • Safeties were bypassed or non-functional, including a disconnected oil pressure safety switch.
  • The grounding was unsafe, with trace voltage found on ground wires and shocks reported by technicians.
  • Electrical terminals were loose, and motor starters were improperly set, sized, and wired.
  • The control wiring was disorganized and had been spliced many times over the years contributing to ongoing troubleshooting issues and operator confusion.

Cooling Tower & Water System Issues

  • Tower nozzles were clogged with scale, reducing cooling efficiency.
  • Improper bonding and grounding posed safety hazards for service personnel.
  • The customer lacked proper water treatment and chemical management procedures.

Air Distribution & Comfort Concerns

  • Inside the building, airflow design flaws were evident—air handler operation caused light fixtures in the sanctuary to sway.
  • There were visible signs of poor air balancing, and no structured monitoring or building automation was in place to track performance or issues.

AFTER: Comprehensive HVAC System Upgrade

Following a full system evaluation, we performed a complete overhaul of the existing HVAC equipment and controls to improve performance, reliability, and energy efficiency. Key upgrades and improvements included:

Mechanical Improvements

  • Removed damaged compressor components and refrigerant/condenser water lines.
  • Installed spring isolators under the compressor and stand to reduce vibration.
  • Re-piped and properly sized suction and discharge lines with vibration absorbers, ball valves, flanges, and a discharge muffler.
  • Replaced compressor suction and discharge service valves.
  • Added new liquid line sight glasses, solenoid valves, TXVs (35-ton balance port), and dryer cores.
  • Installed a suction accumulator.
  • Installed new safeties: high pressure switch, low pressure switch, oil pressure switch, and relief valve.

Electrical & Control Upgrades

  • Installed new VFDs (Variable Frequency Drives) for the evaporator fan, cooling tower fan, and condenser water pump.
  • Replaced the two improperly sized 90-amp motor starters with one new 250-amp motor starter and cleaned up control wiring for optimal function.
  • Integrated a fully customized Automated Logic Building Management System (BMS) with Shane Aldrich at Logical Solutions (lsicontrols.com) for full monitoring and proper control of the unit (monitoring points available upon request).
  • Installed a new flow switch to prevent compressor operation without proper water flow.

Water System Enhancements

  • Installed a new condenser water pump and coordinated with a chemical treatment company to treat tower water properly.
  • Replaced and cleaned clogged cooling tower nozzles.
  • Reworked piping between the condenser barrel and 3” existing condenser water lines, added drain valves to reduce winter water retention.

Service, Clean-Up & Commissioning

  • Removed all unused conduit, wiring, and outdated controls.
  • Cleaned the evaporator coil and air handler with coil cleaner and bacteriostat spray.

Results:

The upgraded system now operates within optimal performance ranges, offering improved reliability, efficiency, and control. This comprehensive overhaul prepares the facility for long-term operation with a significantly reduced risk of future breakdowns. A Preventative Maintenance contract will be in place to ensure the system continues to run at peak performance, allowing us to proactively alert the customer when repairs or upgrades are recommended.